ELIMINATION OF CHANGE OVER BY RE-DESIGNING THE FIXTURE

Dr. M.HENRY XAVIERInternal Guide

P.RAJAExternal Guide

HARI SHANKAR .G (113011114035)

DHANDAPANI .C(113011114307)

VINOD KUMAR.P(113011114327)

COMPANY PROFILE

Company Name BRAKES INDIA,Padi.Established 1962Net Worth 128 m USDSales (2011) 591.80 m USDEmployees 6655Engineers 980Built up Space 1000,000 Square feet Mfg Locations 12No. Customers 70Certifications TS16949, ISO 14001,TPM*,Deming**

MAJOR CUSTOMERS OF BRAKES INDIA

PRODUCTS MANUFACURED

CALIPERS

BRAKE HOSE& CLUTCH HOSE ASSY.

BRAKE FLUID FRICTION MATERIAL SEALS

BOOSTER ASSY CASTINGSDRUM BRAKES

HCV BRAKE

CALIPERS

ABSTRACT The aim of project is to eliminate the change over time of Wheel Cylinder

unit by redesigning the testing clamp for reducing the failures and retest, that mostly gets rejected while conducting the four types of tests (Vacuum test, Stroke test, Bleed test, Air-leak test) on wheel cylinder test rig during the replacement of job. This redesign of clamp for conducting the Air leak test is done on the motive of replacing the usage of two different fixtures for testing two different Wheel cylinder models that does not need to be changed for the production of a particular model. So, the operator does not need to change the fixture every time when another model comes for the production. Our project is directed towards finding a solution

• To avoid changing of testing clamp for every wheel cylinder model.• To make the operator easy to work. • For Less Rejection of jobs or failure rate.

Wheel Cylinder terminology

CHANGEOVER Changeover is the process of converting a line or

machine from running one product to another. Changeover times can last from a few minutes to as much as several weeks in the case of automobile manufacturers retooling for new models.

Changeover can be divided into the 3 Ups:

Clean-up Set-up Start-up

FINDING THE PROBLEM BY TRADITIONAL SHINGLEY’S PROCESS

1.REGONITION OF NEED DATA COLLECTION: Two weeks of data study, Time study, procedure study on the jobs and

machines had taken. Collected information and made a study over the jobs. Finally decided to have a project on rejection of failure jobs.

0

50

100

150

200

250

300

350

400

450

500

0%

20%

40%

60%

80%

100%

Ass

embl

y -1

3;

Labe

ls; 0

Ass

embl

y -0

6;

Labe

ls; 0

Ass

embl

y -0

5;

Labe

ls; 0

Ass

embl

y -0

4;

Labe

ls; 0

Ass

embl

y -1

1;

Labe

ls; 0

Ass

embl

y -0

9;

Labe

ls; 0

Ass

embl

y -0

8;

Labe

ls; 0

Ass

embl

y -1

2;

Labe

ls; 0

Ass

embl

y -0

2;

Labe

ls; 0

Ass

embl

y -0

1;

Labe

ls; 0

PARETTO DIAGRAM

Vital Few Useful Many Cumulative% Cut Off %Assembly line

Ret

est Q

uant

ity

Cum

ulat

ive

%

[42]

PROCESS FLOW CHART

2.DEFINITION OF PROBLEM: The problem can be defined by 4W+1H Method. What - Fail, fault and Re-test problem. Where - at Assembly line-13. When - Quiet Frequently particularly on changing the specified

wheel cylinder model during testing. Who - Operator notices the problem. How - To reduce the severity or occurrence as much as

possible.

SUMO GOLD BOLERO

TESTING SEQUENCE IN ASSEMBLY LINE

1. Sealing rubber damage

2. low Clamping pressure

3 . More Fail After Change Over

4. Port Sealing Arm Misalignment

5. Wrong fixture selection

6. Wrong loading

CAUSES OF THE PROBLEM

More fail after the changeover

During the changeover port sealing adaptor height wrongly set

After the changeover Port sealing shifted

Height setting is manual control

4.ANALYSIS OF THE CHAGE-OVER PROBLEM :

Fixture design

5.ANALYSIS OF THE MISALIGNMENT PROBLEM :

Port sealing arm soft materiel

Swing arm mounting face damaged

Port sealing arm orientation misalignment

During port clamping & de clamping arm damaged

Fixture design

Wheel cylinder more fail

7.SOLUTION OF THE PROBLEM: 1.Eliminate the setting height and commonise the fixture for both models. 2.The new fixture that suits for both the models is designed and implemented. 3.The fixture’s adaptor and arm should be changed to avoid the misalignment because of damage in the mounting face. Therefore swing arm hardness to be increased.

6.IMPORTANCE OF THE PROBLEM

1.Cell Overall equipment effectiveness will reduced.

2.Difficult to meet the customer demand

3.Retest time will increase

4.Possibility of rejection part to meet the customers.

5.Operator can confuse due to frequent fails.

DRUM BRAKE LINE

Wheelcylindertesting

fail

LINE STOP

Due to wheelcylinder fail customer line stop

Impact Of The Job FailWHEEL CYLINDER ASSEMBLY LINE

EXISTING FIXTURE

35 MM 15 MM

SUMO GOLDBOLERO

COUNTER MEASURES ON THE ANALYSIS OF CHANGE-OVER PROBLEM: 1.ELIMINATE THE HEIGHT SETTING.2.COMMONIZE THE FIXTURE FOR ALL PRODUCTS

COUNTER MEASURES ON THE ANALYSIS OF MISALLIGNMENT PROBLEM: 1.ARM TO BE HARDEN

HOW WE ARE CHOOSING COMMON ADOPTER

Trial & Error Method

S.NO SUMO GOLD BOLERO

1. Adopter 35mm Fail Ok

2. Adopter 20mm Ok Fail

3.Adopter 30mm Fail Ok

4. Adopter 22mm Fail Fail

5. Adopter 23mm Ok Ok

6. Adopter 24mm Ok Ok

7. Adopter 25mm Ok Ok

We are choosing 25mm adopter for safe and good clearance between job to top dead Center (TDC)

RESULT :

Adopter __mm + Nylon Rubber 15mm + Harm Thickness 12mm

Designed Fixture Drawing Update